Carton construction



y 31, 1966 o. GJESDAL 3,253,768

CARTON CONSTRUCTION Filed May 18,. 1964 2 SheetsSheet 1 ATTORNEVS O. GJESDAL CARTON CONS TRUCTI ON May 31, 1966 2 Sheets-Sheet 2 Filed May 18, 1964 INVENTOR. OLAV GJESDAL BY wr M' Mfl M ATTORNEYS United States Patent 3,253,768 CARTON CONSTRUCTION Olay Gjestlal, Toledo, Ohio, assignor to Owens-Illinois Glass Company, a corporation of Ohio Filed May 18, 1964, Ser. No. 368,083 8 Claims. (Cl. 229-37) The present invention relates to carton constructions. More particularly, the present invention relates to a carton which, by reason of its novel features of construction, permits nesting of partially assembled cartons.

The cartons to which the present invention relates are generally formed of a relatively stiff, sheet-like material such as corrugated board, solid fiberboard, chipboard or cardboard. The corrugated board, of course, is formed of two facing or liner sheets having a-dhesively secured therebetween a convoluted corrugating medium. Solid fiberboard is in some applications interchangeable with corrugated board. The invention will be described in connection with a solid fiberboard or cardboard construction, although it should be appreciated that a variety of relatively stiff, sheet-like candidate materials may be used.

Cartons formed of such materials are generally die cut, slit and scored; the latter providing relative foldability of the components defining, when assembled, the desired carton or container.

Cartons and/or containers formed of relatively stiff, sheet-like material are generally laid out in flat form by acombination of operations including scoring, slitting, slotting, printing and decorating. Not all of these operations are required for every carton. In any event, the carton, after completion of the necessary operations, constitutes a flat blank which possesses the configuration, flaps, scores, etc., whereby it may be folded into its final shape and secured there by stitching, stapling, gluing, taping or the like. Usually the blanks are shipped fiat to the consumer in the interest of shippmg space savings. The consumer then assembles the carton or container by the aforesaid stapling, stitching, gluing and/ or taping techniques as his needs dictate.

In many packaging operations, it is desirable that the carton or container be partially preassembled, leaving one end open for insertion of the product. Thus, the consumer may not wish to include a carton assembly step in his operation. More frequently, preassembled cartons are desired where the product to be packaged is not convenient to a carton assembly station. Typical are many farm pro-ducts and other items grown in the field. Additionally, partial preassembly into form receptive of goods is undesirable since the empty cartons occupy a considerable amount of space.

It is a principal object of the present invention to provide a carton construction which, by reason of novel features of design, provides a stacking capability to partially assembled cartons, principally by a nesting feature.

It is also an object of the present invention to provide a novel design for a die cut blank which is erectable into a partially assembled condition characterized by telescopic nestability with like cartons, whereby a plurality of such cartons can be conveniently maintained proximate the user, but occupying a minimum of space.

It' is also an object of the present invention to provide such a carton construction, the blank -for which can be manufactured with'relative ease and can be partially erected into nestable form with a minimum of difficulty.

It is likewise an object of the present invention to provide a carton which, in addition to being nestable by reason of novel constructional features, includes novel tab or flap provisions for preventing the nested cartons from becoming too tightly nested and, at the same time, serves 3,253,768 Patented May 31, 1966 'ice as a barrier against leakage of powdered or granular contents.

It is also an object of the present invention to provide a carton construction which, by reason of its design, is nestable with cartons of like construction, where-by a plurality of such cartons or containers may be partially assembled (e.g., readied for reception of product), then nested and furnished to the situs of use wherein the worker can remove the individual cartons in sequence, fill them with the product to be contained, and thereaft pass them on for final closure and shipping.

The packaged carton constructions to which the invention relates are of particular utility in those applications where conventional carton erecting mechanisms, such as staplers, stitchers and tape applicators, are not conveniently employed; thus, in the situation wherein the product is to be inserted into the package away ctrom the factory. Thus, the shipment of produce and a host of other products which are not factory produced, it is frequently desirable to have a plurality of empty containers stacked in a nesting relationship so as to occupy a minimal amount of space, yet be readily available for use of the packer.

The foregoing, as well as other objects of the present invention, will become apparent to those skilled in the art from the following detailed description taken in conjunction with the annexed sheets of drawings on which there are presented, for purposes of illustration only, several embodiments of the present invention.

In the drawings:

FIG. 1 is a plan view of a knocked down blank, die cut, scored and slotted in such fashion as to yield a carton fulfilling the primary objects of the present invention.

FIG. 2 is a perspective view of a carton ultimately erected from the blank shown in FIG. 1 and shown ready for reception of the product to be packaged therein.

FIG. 3 is a perspective view similar to FIG. 2, but showing the configuration of the corners of the carton at a position intermediate its nested relationship and the ultimate package receiving configuration shown in FIG. 2.

FIG. 4 is a schematic, side sectional view illustrating a plurality of empty cartons of the present invention in nested relationship ready to be used by the packer.

FIG. 5 is a top sectional view of a carton construction in accordance with the present invention and specifically showing the configuration of the cornersof a carton which is nested within the tubular confines of another carton (the latter not shown).

FIG. 6 is a plan view of a knocked down blank which has been die cut, scored and slotted in such fashion as to yield, when erected, a carton constituting another embodiment of the present invention capable of fulfilling the primary objects of the present invention as well as additional objects.

FIG. 7 is a perspective, interior view looking downwardly at a corner of the carton construction erected from the blank shown in FIG. 6; portions of the constructions being broken away for clarity.

FIG. 8 is a top view looking down into the open end of an assembled carton erected from the blank shown in FIG. 6.

FIG. 9 is a perspective view looking from the outside at the bottom of the carton erected from the blank shown in FIG. 6; this view serving to show the nonleaking feature in accordance with this present .em bodiment.

Referring now more specifically to the drawings, the blank 11 is composed principally of foldably connected side wall panels 13, 15, 17 and 19, separated respectively by principal intersection score foldlines 20, 21 and 23.

Lateral side edges 25 and 27, when assembled,-will constitute one corner of the erected carton as will the principal intersection score foldlines 20, 21 and 23. Foldline 29 defines a top edge of the ultimate carton and separates the side wall panels from associated top closure flaps 31, 33, 35 and 37. The top closure flaps 31, 33, 35 and 37 are respectively separated by slots 80 as shown in FIG. 1, lending relative foldability of the top closure flaps in the sealing operation. The bottom terminus of the side wall panels 13, 15, 17 and 19 is defined by a foldline 46 which also defines the foldable connection of bottom closure flaps 41, 43, 45 and 47, foldably connected respectively to side wall panels 13, 15, 17 and 19. Each of the bottom closure flaps 41, 43, 45 and 47 are provided with an in-line foldline 50 spaced a slight distance from the foldline 4t), defining therebetween associated flexible segments 13a, 15a, 17a and 19a, separated from corresponding side panels 13, 15, 17 and 19 by the foldine 40. The segments 13a, 15a, 17a and 19a are foldable between one extreme position, co-planar with the side walls, and another position, co-planar with the bottom wall flaps in their usual perpendicular relationship to the side walls. The provision for the foldline or score line 50 in each of the bottom flaps defining the segments 13a, 15a, 17a and 19a represents a particularly desirable feature of the present invention.

Each of the side wall panels is provided with a pair of fold score lines, each of which is identified by the reference numeral 60. In eachcase, the foldline is spaced slightly from the lateral boundaries of the individual side wall panels. Thus, a foldline 60 is spaced slightly from the left lateral edge and also, in panel 13, from the intersection line 20. Similarly, side wall panel 15 contains a pair of foldlines 60, one spaced from the intersection line 20 and one spaced to the left of intersection line 21. In similar fashion, side panel 17 is provided with a foldline to the right of intersection line 21. Panel 17 also includes foldline 60 to the left of intersection line 23; while panel 19 has a pair of foldlines 60, one of which is spaced to the right of intersection line 23 and one is spaced to the left of the lateral edge 27. The foldlines 60' are in parallel relationship to these intersection lines 20, 21 and 23 and extend beyond the foldline 29 into the top closure flaps 31, 33, and 37.

The bottom closure flaps 491, 43, 45 and 47 are separated by notches 65 which are defined by parallel edges 65a and 65b constituting, respectively, lateral free edges of adjacent flaps and by an inverted V configurated edge 65c, the legs of which connect to the edges 65a and 65b and the apex of which lies to the intersection of foldline and the principal intersection lines 20, 21 and 23. The bottom closure flap 41 includes an outer lateral edge which represents one-half of a notch configuration. Similarly, bottom flap 47 includes an outer lateral edge constituting one-half of a notch configuration. By reason of the configuration of these outer lateral free edges on the flaps, when the lateral free edges 25 and 27 of the blank are placed in mating contact and then taped, the bottom closure flaps 4.1 and 47 will define therebetween a notch having the same configuration as that of notches 65.

With the construction as thus far described, it will be appreciated that edges 25 and 27, when placed in abutting contact and taped, will yield a tubular structure with flaps at each end. The tube walls definedby the panels 13, 15, 17 and 19 are separated by the corner intersection lines 20, 21 and 23 and the abutting edges 25 and 27. The intersection lines will be found to possess a considerable degree of flexibility by reason of the cooperative relationship of these intersection lines 20, 21 and 23 (and the corner defined by the taped abutting edges 25 and 27) and the parallel score foldlines 60 on each side of these respective corners 20, 21 and 23 and the one defined by the abutting of edges 25 and 27. In particular, by reason of these features, the perimeter of the tube is effectively variable since reverse foldability is possible with the plurality of score foldlines 60 prox- 4; imate the normal corner. Actually, of course, each individual carton in nested relationship will assume a slightly different configuration regarding the corner folds and the bottom wall segments or bevels 13a, 15a, 17a and 19a. Thus, the latter segments in the topmost of a stack of nested cartons assume almost planar relationship with the associated side walls. In contrast, the bottommost carton has its segments 13a, 15a, 17a and 19a in coplanar relationship with the bottom wall.

The blank is shown folded into ultimate erected assembly in FIG. 2. Edges 25 and 27 abut, secured by tape 25a, to define one corner of the carton. The carton, as erected, defines a major perimeter corresponding to the distance between the lateral edges 25 and 27 or the sum of the individual side wall panels 13, 15, 17 and 19. In this position, the bottom wall flaps 41, 43, 45 and 47 are brought into alternate overlapping relationship and stapled or stitched. The score foldlines 40 and are preferably impressed on both sides of the sheet material of the blank 11 in order to provide relative foldability in either direction. With the construction as just described, a carton 70, such as shown in FIG. 1, may have nested therewithin another carton of like configuration and assembled as just described and formed of the blank as shown in FIG. 1. The carton of this invention, by reason of the corner folds 60 and segments 13a, 15a, 17a and 19a, possesses overall dimensional variability.

By reason 'of the cooperative relationship of the plurality of foldlines 60 and the foldline 40 defining the segments 13a, 15a, 17a and 19a, the second carton inserted axially into the carton will have, by reason of the inherent flexibility provided by these foldlines, the ability to assume the configuration shown and identified by the reference numeral 71 in FIG. 4. In other words, as illustrated there, one of the bottom Wall segments 13a will assume an angular attitude with the horizontal, such that the ultimate cross sectional area or the effective perimeter of the carton 71 is less than that of the carton 70. Similarly, a third carton 73 nested down into the carton 71 will, by reason of the cooperative relationship of the foldlines 60 and the foldline 40, cause the bottom wall segment 14a, between foldlines 40 and 50, to assume a sharper attitude with respect to the horizontal, whereby the effective cross sectional area of the carton 73 proximate the bottom. wall is still less than that of the carton 71.

In accordance with a further embodiment of the present invention, the blank may be die cut, scored and slotted in the manner shown in FIG. 6. This blank 311 is identical to the blank 11 shown in FIG. 1, excepting with respect .to certain features, components and constructional details which are identified by numerals in the series. All other panels, foldlines, flaps, etc., of the blank 11 will bear the same reference numeral as that of the blank 11. The same applies to the carton 70 shown in FIGS. 7, 8 and 9. With most elements, the numerals will be left off in order not to interfere with the clarity of disclosure concerning the features and constructional details which distinguish this embodiment from that of FIG. 1. The primary difierence of the blank 311 of FIG. 6 from the blank 11 of FIG. 1 is that the bottom flap 141 is a full flap rather than a partial flap 41 as formed by notches 65 as shown in FIG. 1. Similarly, the flap is a full fiap rather than a partial flap 45 in the blank of FIG. 1. The full flap 141, however, includes relatively foldable lateral tabs 142 and 143, separated from the flap proper by a cut 144 and spaced parallel cut 144*. The cuts 144 and 144' terminate at the foldline 50. The tabs 142 and 143 are relatively foldable, both about foldines and 171. The same reference numerals are used to identify the foldlines about which tab 143 is foldable. The full flap 145 is similarly configured, die cut and scored as flap 141.

Thus, cuts 173 and 173a define lateral tabs 174 and 175 which are each foldable about foldlines 176 and 177.

The blank 311 can be folded into a tube 180 by bringing the opposed free edges 25 and 27 (of panels 13 and 19) together and taping them with a tape strip 181. Thence, the bottom wall flaps are folded into normal relationship; the flaps 141 and 145 first being folded inwardly into co-planar relationship and the outer flaps 43 and 47 thence folded over into co-planar relationship with each other and flush against flaps 141 and 145. With the carton erected into assembed configuration as shown in FIGS. 7 and 8, the tabs 143 and 142, by reason of their relative foldability via foldlines 170 and 171, will assume a somewhat askew position, projecting angularly towards the center of the carton and upwardly. Similarly, the tab 174, associated with the bottom flap 145 and also with the side wall panel 17, will assume a similar inwardly and upwardly askew positioning. The tab 175 is not shown in FIG. 7.

These flaps serve the purpose of preventing the nextto-be-nested carton from being telescopically inserted too far into the next lowermost carton. This has the desirable result of preventing the cartons from being too tightly nested together that they cannot be pulled apart, one at a time, as needed.

FIG. 9 illustrates that once a carton has been removed from the stack, the tabs 142 and 143 and 174 and 175 can individually be pushed down into planar relationship with their associated bottom Wall flaps 141 and 145, respectively, whereby they aid in sealing the carton against accidental loss of the granular or powdered contents. Thus, in FIG. 8, it can be seen that the tabs 142 and 143 lie in planar relationship withthe flap 41 while, similarly, tabs 174 and 175 lie in planar relationship with the flap 145.

Referring now to FIG. 9, we see how the tabs 143 aid in preventing leaking of powdered or granular contents. In FIG. 9, the carton is viewed from the bottom-with the side wall 13 and the bottom closure flaps 43 and 47 folded over into co-planar relationship. Underlying the flap 43 is flap 141 (shown in dotted outline) and also the foldable tab 143 seen in partial full line by reason of the breakway at 190. Were it not for the tab 143 lying flushly in planar relationship with the flap 141 and flush against flap 43, a crack or gap would exist at the point identified by the reference numeral 200. This gap is effectively closed, however, by reason of the existence of the tab 143. Similar gaps are effectively closed by the presence of tabs 142, 174 and 175, although not shown in the interest of simplicity of illustration.

It is a particular novel feature of the present invention that the provisions for the segments 13a, 15a, 17a and 19a cooperate with the plurality of foldlines 60, whereby the corners 20, 21, 23 and the taped corner (formed by abutting edges 25 and 27) can assume a configuration such as shown in FIG. 5, which is somewhat distorted from the normal right angle corner of the outer carton 70 as shown in FIG. 2.

One way of looking at this particular phenomena is to consider that the carton construction including the features as described herein can assume a cross sectional area which is less than the ultimate cross sectional area wherein the corners define right angles. Alternately, one

can consider the relationship of the corner fold, the fold scores and the bottom wall segments 13a, 15a, 17a and 19a as providing an effective variable perimetric dimension, whereby axial nesting is accomplished.

Any number of cartons employing the construction as disclosed herein may be nested together, providing the convenience noted hereinabove. For clarity of illustration, however, only three such nested cartons 70, 71 and 73 are shown, for example, in FIG. 4. The ultimate packer, it will be appreciated, furnished with a supply of nested cartons or containers as shown in FIG. 4, can readily remove the innermost by grasping the top flap and pulling it from the remainder of nested cartons. The carton can then be filled with the intended product and the top closure flaps interlocked by the conventional alternate interfolding of the top closure flaps. Alternately, the top closure flaps may be stapled, stitched, glued, taped, or otherwise secured.

.Although a simple four-walled rectangular carton construction has been illustrated in the drawings, it will be appreciated that the carton may be composed of a plurality of sides, e.g., anywhere from three to eight or more.

The bottom and top closure flaps may be so dimensioned, by appropriate die cutting and scoring, as to provide either full overlap flaps or partial overlap flaps.

The important consideration involved in the design and construction of cartons in accordance with the present invention is that they employ corner constructions, including an inherent perimetric dimensional flexibility determined by the spacing of the score line on either side of the corner intersection lines and the distance between the foldline in the bottom closure flap and the lower edge score of the side wall panels.

As indicated hereinabove, the container or carton may be fabricated of a variety of materials of construction, limited only by the characteristic of possessing a certain amount of inherent stiffness but, at the same time, being capable of being scored or otherwise provided with a weakening line which lends relative foldability of spaced components of the sheet without destroying the sheet proper. Corrugated board, fiberboard, chipboard and cardboard are the most common representative materials possessing the foregoing enumerated characteristics.

While I have disclosed a preferred manner of fabricating a carton construction, it will be appreciated that the principles and techniques will be of Wider application than specifically disclosed. As a consequence, it is intended to include all obvious modifications as well as carton constructions employing minor departures and variations of the carton disclosed herein, unless to do so would be violative of the scope of the appended claims.

I claim:

1. A carton possessing perimetric flexibility so as to permit nesting of a plurality of said cartons, said cartonscomprising a connected plurality of wall panels defining the closed perimeter of said carton; said panels each including a pair of score lines, each line spaced slightly from the line of intersection between panels; closure flaps foldably connected to said panels, each flap bearing a score foldline parallel to and spaced slightly from the intersection line between the flap and its associated panel, said flaps being separated by a notch, said notch edges proceeding from the outer free edge of the flap in perpendicular relationship to the intersection line between a panel and its associated flap and terminating in an inverted V contour, the apex of which lies on the intersection of the foldline separating the panel end flap and the intersection line between panels.

2. A carton possessing perimetric flexibility so as to permit nesting of a plurality of said cartons, said carton comprising a connected plurality of four wall panels defining the closed perimeter of said carton, said panels each including a pair of score lines, each-line spaced slightly from the line of intersection between panels, closure flaps foldably connecting to said panels, each bearing a score foldline parallel to and spaced slightly from the intersection line between the flap and its associated panel, said closure flaps being separated by a notch, and four foldable tabs, one each being connected to a lateral edge of two of said flaps separated by a third flap.

3. A cartonas claimed in claim 2, wherein said tabs I are foldably connected to the spaced flaps at the space between the score line on said flaps and the intersection line between the flap and its associated panel.

4. A carton as claimed in claim 3, wherein the foldline separating said tabs from said flaps is at an angle to said intersection line.

5. A carton construction comprising a plurality of connected side wall panels defining the perimeter of said carton; said side Wall panels being separated by principal intersection lines in spaced parallel relationship, each of said side wall panels having a foldably connected flap normally disposed to the associated side Wall panel to thereby define, together with adjacent flaps, a bottom wall for said carton, means for securing said flaps together; said carton including a plurality of parallel score foldlines sufilcient in number to provide one on each side of said principal intersection lines and each flap including a score foldline parallel to and spaced from the foldline separating said flap from the associated side wall panel; said foldably connected flaps having notches between lateral edges thereof, said notches having a root of inverted V configuration, the apex of which lies at the intersection I of the principal intersection line and the foldlines separating the side panel and the connected flap; said score foldlines located in said side walls, and said score foldlines in said bottom wall flaps cooperating to provide perimetric dimensional variability, whereby a plurality of like constructed cartons may be nested with their corresponding side walls in generally flush telescopic relationship.

6. A planar blank formed of relatively stiff, sheetlike material; said blank comprising a plurality of sideby-side panels separated by parallel scored intersection lines, the terminal end panels having lateral free edges parallel to said intersection lines, a plurality of flap extensions foldably connected to said panels respectively; said flaps being separated by a notch defining lateral edges of said flaps; said blank including a plurality of parallel score lines which are parallel to the intersection lines and being located one on each side of the intersection lines and one being spaced proximate each of said lateral free edges of said terminal end panels; said flaps each including a fold score line spaced parallel to and outwardly from the foldline connection between said panels and the flaps, and tabs foldably connected to the lateral edges of two flaps separated by a third flap.

7. A blank as claimed in claim 6, wherein said tabs are connected to said flaps in the edge region between the fold score line on said flaps and the foldline connection between the panels and flaps, and said tab connection foldline is at an angle with said score line.

8. A carton construction comprising a plurality of connected side wall panels defining the perimeter of said carton; said side wall panels being separated by principal intersection lines in spaced parallel relationship, each of said side wall panels having a foldably connected flap normally disposed to the associated side wall panel to thereby define, together with adjacent flaps, a bottom wall for said carton, means for securing said flaps together; said flaps being separated by a notch; said carton including a plurality of parallel score foldlines sulficient in number to provide one on each side of said principal intersection lines and parallel thereto, and each flap including a score foldline parallel to and spaced from the foldline separating said flap from the associated side wall panel; said score foldlines located in said side Walls and said score foldlines in said bottom wall flaps cooperating to provide perimetric dimensional variability whereby a plurality of like constructed cartons may be nested with their corresponding side walls in generally flush telescopic relationship.

References Cited by the Examiner UNITED STATES PATENTS 1,255,133 2/1918 Carr. 2,097,433 11/1937 Clark et al 229-37 2,573,524 10/1951 Weisberg et a1. 22937 3,114,492 12/1963 Engst rom.

JOSEPH R. LECLAIR, Primary Examiner.

FRANKLIN T. GARRETT, Examiner.

D. T. MOORHEAD, Assistant Examiner. 

1. A CARTON POSSESSING PERIMETRIC FLEXIBILITY SO AS TO PERMIT NESTING OF A PLURALITY OF SAID CARTONS, SAID CARTONS COMPRISING A CONECTED PLURALITY OF WALL PANELS DEFINING THE CLOSED PERIMETER OF SAID CARTON; SAID PANELS EACH INCLUDING A PAIR OF SCORE LINES, EACH LINE SPACED SLIGHTLY FROM THE LINE OF INTERSECTION BETWEEN PANELS; CLOSURE FLAPS FOLDABLY CONNECTED TO SAID PANELS, EACH FLAP BEARING A SCORE FOLDLINE PARALLEL TO AND SPACED SLIGHTLY FROM THE INTERSECTION LINE BETWEEN THE FLAP AND ITS ASSOCIATED PANEL, SAID FLAPS BEING SEPARATED BY A NOTCH, SAID NOTCH EDGES PROCEEDING FROM THE OUTER FREE EDGE OF THE FLAP IN PERPENDICULAR RELATIONSHIP TO THE INTERSECTION LINE BETWEEN A PANEL AND ITS ASSOCIATTED FLAP AND TERMINATING IN AN INVERTED V CONTOUR, THE APEX OF WHICH LIES ON THE INTERSECTION OF THE FOLDLINE SEPARATING THE PANEL END FLAP AND THE INTERSECTION LINE BETWEEN PANELS. 